ProcessApex Distillation

Distillation Column Component

Distillation columns perform a large share of component separations for the processing industries. These operations are very energy intensive. Many factors affect the performance of a distillation column. Some of these are mechanical; tray fouling leading to loss of efficiency and higher reflux/vapor demands which in turn increases energy usage. Some are operational decisions; pressure higher than necessary increases energy usage. Control settings; over purifying products, wastes energy and potentially gives valuable product away. In some cases the control design itself is responsible for poor performance because it can not maintain stable operation. Being aware of the critical parameters and quickly diagnosing the root cause of inefficient operation is an essential part of an asset performance program.

  Real-Time Results Tracking

Improve Results

With up-to-the-minute analysis of column performance, you can immediately make improvements. ProcessApex provides detailed real-time analysis, including:

• Percentage Recovery
• Operating Costs
• Stage Performance
• Mass & Energy Balances

Now process engineers and operators can make decisions with much accuracy, and more confidence.

Identify Constraints

Where can your column improve? ProcessApex pinpoints bottlenecks, so you know exactly where the constraints are holding you back.

Track Energy Usage

Distillation operations may account for 40% of energy consumption in oil refineries and petrochemical plants. Shouldn't you understand exactly where the energy is being used?

ProcessApex monitors each energy stream, and its associated costs. processApex will even pinpoint where there are opportunities to conserve.

ExperTune's ProcessApex helps you evaluate, monitor, and diagnose your distillation column performance. The distillation component can handle a typical 2 product distillation column. Some of the metrics available for this component include: recovery, energy and mass balances, stage performance, opportunity gap for products, and control design.

  Powerful Reporting

Web-Based Trends and Reports Make It Easy to Use

ProcessApex is entirely web-enabled. You get reports, trends, and dashboards designed to give you visibility and insight into distillation column performance. Accessible throughout your secure company network, with no client software to load.

Trending of Distillation Column Results

Different Reports for Different Users

ProcessApex can provide specific information to operations, management, or engineering personnel. The standard reports can clearly spell out the technical. operational, or management details needed to make an improvement.

Report Showing Savings Opportunities

Some of the assessments are designed to provide "what-if" or potential opportunity values. When the column is producing products over target specifications on purity, money is being lost. There are assessments that calculate the monetary value of the product and energy losses. All of these metrics are also maintained in a historian for trending.

  Accurate, Useful Analysis

Column Models From Real-Time Data

With all the real-time data streaming in from your control system, ProcessApex can model the actual performance of your distillation column. With this information you can:

1. Develop better understanding of column behavior
2. Compare actual performance to theoretical
3. Know immediately when column behavior changes

Get greater insight into your distillation column's performance with ProcessApex.

Controller Design Guidance - From Greg Shinskey

Distillation is an interactive process: adjustments to one end of the column end up affecting the other end. The control strategies used to control the column and its product purities is an integral part of the process operation.

F. Greg Shinskey is a legend in the world of process automation. His book "Distillation Control" is the reference book for control of distillation columns. Mr Shinskey was integrally involved in the design of ExperTune's ProcessApex.

Using Greg Shinskey's decision process, ProcessApex analyzes the column operation and determines the best pairings of variables to control the top and bottom compositions to minimize interactions and stabilize the column variables.

Consistent Results

The ideas behind each of the ProcessApex components are:

1. Consistent calculations
2. Easily accessed information
3. Create a historical record
4. Enable faster decisions
5. Identify opportunities for improvement
6. Value the opportunity when possible

Please contact us if you would like additional information, also if you have specific metrics you would be interested in for a particular component.